RISO SCOTTI Boosts Production Efficiency and Quality with INOXPA's Automated Plant Solution
The Customer
Riso Scotti is one of Italy’s most established manufacturers and distributors of rice and cereal-based products. Founded in 1860, the company has grown into a global brand exporting to more than 60 countries. Over the years, the company has managed to create a reputation for itself by combining traditional knowledge of growing rice with modern food innovation.
Apart from the rice products, the company also manufactures biscuits, sweet snacks, and a variety of plant-based drinks made from oats and soy. With the increasing demand for these drinks around the world, it has become a priority to ensure that the quality is maintained while at the same time improving the efficiency of production. The final packaging process of these drinks also uses modern technology, such as a bottle filling machine.
The Challenge
To keep pace with the increasing global demand for plant-based beverages, Riso Scotti identified several goals for its production upgrade. The company wanted to raise its production capacity on a daily basis without compromising the quality of its products.
At the same time, the company wanted to automate and streamline its processing operations to reduce manual intervention and improve production consistency. Another important objective was to optimize the use of raw materials and energy throughout the process.
These objectives would be achieved by having an advanced automated production line that would be compatible with other packaging machines, like an automatic bottle filling machine, so that the beverage products are filled quickly and accurately.
Why INOXPA
For these lofty aims to be achieved, INOXPA was selected to be the technology partner in this undertaking. The company is well known for its expertise in designing and installing integrated process systems for the food and beverage industry.
INOXPA provided a solution for maximum productivity and quality control. The advanced process equipment, combined with automation, ensures that the production steps are completed before the product is packed by a packaging machine, such as an automatic liquid-filling machine, which is a critical part of the beverage manufacturing process.
The INOXPA Solution
INOXPA designed and implemented a fully automated plant management system capable of producing up to 12,000 litres per hour of plant-based drinks. The system was designed to minimize the use of raw materials as well as the cost of energy, thus making the process more sustainable.
The production line was split into five process stations:
- Preparation, mixing, and heating – Flow rate of 9,000 L/h
- Storage – Six 10,000 L tanks with a pneumatic valve manifold for automated transfer
- Cooling and recirculation – Flow rate of 14,000 L/h
- Pasteurization and filtration – Flow rate of 6,000 L/h
- Dissolution and final cooling – Flow rate of 12,000 L/h
In addition, the solution included the integration of existing equipment, such as the homogenizer, decanter, and storage tanks, into the new system. After the beverages have gone through the process, they are ready to be moved into the packaging area, which contains a bottle filling machine, for bottling purposes.
Key Results and Benefits
The automated system ensured that the production facility realized a number of benefits. The first benefit was an increase in productivity, as the system automated most tasks, reducing the need for manual control. The system also enables operators to operate the entire facility through specialized software at a single workstation.
The design improvements also enabled better use of raw materials and energy resources. Systems that utilize heat have been used to improve efficiency.
Continuous production with minimal downtime has also been achieved. The integration of automated process stages and subsequent equipment, such as an automatic bottle filling machine, also ensures smooth flow of products. In addition, the automatic liquid filling machine ensures that there is no waste of the product, as well as accurate filling quantities.
Other benefits include consistent product quality, improved repeatability, and full Industry 4.0 compliance. This compatibility enables the company to benefit from digital innovation grants, as well as enhances its efficiency.
In modern packaging systems, the high-quality automatic liquid filling machine can be used in conjunction with the automatic bottle filling machine to cater to high production rates without affecting the quality.
The Outcome
Thanks to the automation expertise of INOXPA, Riso Scotti has a modern, efficient, and sustainable production line for its plant-based drinks. The new production line meets the growing demand for the product while ensuring the quality standards that the brand is famous for.
Right from the processing stage to the final packaging, the use of machines such as the bottle filling machine is critical to ensure that all bottles coming out of the production unit meet the quality standards. This enables the company to compete effectively in the fast-growing international market for plant-based beverages.
FAQs
- Why did Riso Scotti upgrade its production system?
Riso Scotti upgraded its production system to meet the growing global demand for plant-based beverages while improving efficiency, reducing manual intervention, and maintaining consistent product quality.
- What solution did INOXPA provide to Riso Scotti?
INOXPA designed and implemented a fully automated plant capable of producing up to 12,000 litres per hour, integrating multiple process stages such as mixing, storage, pasteurization, and cooling into a streamlined system.
- How does automation benefit the production process?
Automation improves productivity, gives consistent product quality, reduces downtime, and allows operators to control the entire system from a single workstation, improving overall operational efficiency.
- What role does the bottle filling machine play in the process?
The bottle filling machine ensures accurate, efficient, and hygienic packaging of the final product, minimizing waste and maintaining uniform filling standards for high-volume production.
